US20100252089A1 - Method for providing a series connection in a solar cell system - Google Patents

Method for providing a series connection in a solar cell system Download PDF

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US20100252089A1
US20100252089A1 US12/734,905 US73490508A US2010252089A1 US 20100252089 A1 US20100252089 A1 US 20100252089A1 US 73490508 A US73490508 A US 73490508A US 2010252089 A1 US2010252089 A1 US 2010252089A1
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layer
transparent conductive
conductive oxide
groove
back electrode
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Edwin Peter Sportel
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Helianthos BV
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/0248—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies
    • H01L31/036—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes
    • H01L31/0392—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes including thin films deposited on metallic or insulating substrates ; characterised by specific substrate materials or substrate features or by the presence of intermediate layers, e.g. barrier layers, on the substrate
    • H01L31/03921—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes including thin films deposited on metallic or insulating substrates ; characterised by specific substrate materials or substrate features or by the presence of intermediate layers, e.g. barrier layers, on the substrate including only elements of Group IV of the Periodic Table
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/0445—PV modules or arrays of single PV cells including thin film solar cells, e.g. single thin film a-Si, CIS or CdTe solar cells
    • H01L31/046—PV modules composed of a plurality of thin film solar cells deposited on the same substrate
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/0445—PV modules or arrays of single PV cells including thin film solar cells, e.g. single thin film a-Si, CIS or CdTe solar cells
    • H01L31/046—PV modules composed of a plurality of thin film solar cells deposited on the same substrate
    • H01L31/0465—PV modules composed of a plurality of thin film solar cells deposited on the same substrate comprising particular structures for the electrical interconnection of adjacent PV cells in the module
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • H01L31/1884—Manufacture of transparent electrodes, e.g. TCO, ITO
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the present invention pertains to a method for providing a series connection in a solar cell system, and to a solar cell system comprising solar cells connected in series.
  • Solar cells also known as photovoltaic cells, generally comprise a carrier and a photovoltaic (PV) layer composed of a semiconductor material provided between a front electrode comprising a transparent conductive oxide (TCO) (on the light-receiving side of the cell) and a back electrode (at the back of the cell).
  • TCO transparent conductive oxide
  • the front electrode is transparent, enabling incident light to reach the semiconductor material, where the incident radiation is converted into electric energy. In this way light can be used to generate electric current, which offers an interesting alternative to, say, fossil fuels or nuclear power.
  • the maximum voltage of a solar cell is determined by the composition of the cell, more in particular by the nature of the semiconductor material, and by the intensity of the incident light. When the surface area of the solar cell is increased, more power is generated, but the voltage re-mains the same.
  • a solar cell is often divided into individual subcells, which are connected in series to form a solar cell system. This is done by establishing a conductive contact, also indicated as interconnect, between the front electrode of one cell and the back electrode of another, while interrupting the front electrode and the back electrode each at a different side of the interconnect so as to prevent short-circuiting.
  • the interconnect and the interrupts must be as close together as possible and the interconnect and the interrupts must be as narrow as possible.
  • series connection is effected as follows: A transparent conductive oxide (TCO) layer that is deposited onto a (glass) substrate is patterned with parallel grooves, which form the interrupts in the front electrode.
  • the photovoltaic (PV) layer that is deposited over the TCO layer is also patterned with parallel grooves, which form the basis for the interconnects between the front electrode of one cell and the back electrode of an adjacent cell.
  • the back electrode is then deposited over the PV layer, and patterned with grooves to form the interrupts.
  • the interconnect is formed by the back electrode material deposited in the groove in the PV layer.
  • WO 2003001602 describes a method for manufacturing a solar cell provided with a series connection via a method using a temporary substrate, which method, int. al., comprises the step of providing a groove from the light-incident side of the final solar cell system through the transparent conductive oxide front electrode.
  • scribing a groove in the TCO layer may result in damage to the material underlying the TCO layer.
  • the debris from this material which may, for example be metal if the underlying material is a metal substrate, can contaminate the solar cell system, and for example cause shunts.
  • This is applicable both when the groove is applied on the TCO layer as such, but also when the scribing step takes place through layers covering the TCO layer, such as the photovoltaic layer and optionally the back electrode layer.
  • the damage to the substrate as such may also detrimentally affect the properties of the system.
  • the provision of the grooves in the TCO layer may result in damage to the underlying PV layer.
  • WO 98/13882 and WO99/49483 describe a method for manufacturing a photovoltaic foil comprising the steps of providing a temporary substrate, which is, e.g., an aluminium foil, applying a transparent conductive oxide layer onto the temporary substrate as front electrode, applying a photovoltaic layer onto the TCO layer, applying a back electrode layer onto the photovoltaic layer, applying a carrier onto the back electrode, and removing the temporary substrate.
  • a groove may be applied through the TCO layer (and optionally through the PV layer and if present the back electrode), onto the temporary substrate, which is then filled with an insulating material.
  • the temporary substrate is then removed through, e.g., an etching process, the groove and the insulating material present therein come into contact with the etchant, which can damage the series connection.
  • a general problem underlying the manufacture of solar cell systems comprising solar cells connected in series is that the number of process steps and the accurate repositioning between the process steps makes for a complicated and cost-intensive process.
  • the present invention is directed to a process for providing a series connection in a solar cell system comprising the provision of a solar cell system comprising a transparent conductive oxide layer, a photovoltaic layer, and a back electrode, wherein the system is divided into at least two individual cells wherein the transparent conductive oxide layer of one cell is connected through a conductive interconnect with the back electrode of an adjacent cell, and the transparent conductive oxide layer is provided with an insulating interrupt on one side of the interconnect and the back electrode is provided with an interrupt on the other side of the interconnect, the process being characterised in that the insulating interrupt in the transparent conductive oxide layer is provided through vitrification of the transparent conductive oxide layer.
  • the present invention also pertains to a solar cell system comprising a transparent conductive oxide layer, a photovoltaic layer, and a back electrode, the system comprising at least two individual cells with the transparent conductive oxide layer of a cell being connected through a conductive interconnect with the back electrode of an adjacent cell, wherein the transparent conductive oxide layer is provided with an insulating interrupt on one side of the interconnect and the back electrode is provided with an interrupt on the other side of the interconnect, characterised in that the insulating interrupt in the transparent front electrode is made up of vitrified transparent conductive oxide. It is noted that interrupts are by their nature always insulating, whether or not this is specified as such.
  • the crux of the present invention is the recognition that an interrupt in the transparent conductive oxide layer (also indicated as TCO layer) can be obtained by vitrifying the TCO.
  • Suitable transparent conductive oxides include indium tin oxide, zinc oxide, zinc oxide doped with aluminum, fluorine, gallium, or boron, cadmium oxide, tin oxide, metal stannates, such as Zn or Cd stannates, and F-doped SnO2, Sb-doped SnO2, p-doped TCO, such as cuprates, for example Sr-based cuprates.
  • the vitrification process transforms the transparent conductive oxide to form a transparent insulating interrupt.
  • the vitrification process can be carried out by providing the TCO layer with energy, for example using a laser, wherein the amount of energy provided is sufficient to vitrify the TCO layer, but insufficient to cut through the layer. Selection of an appropriate vitrification method, including selection of a laser with the appropriate wavelength, is within the scope of a skilled person.
  • UV lasers are generally suitable. Examples include triplet or quadruplet Nd (puls)lasers and eximer (puls)lasers. The light emitted by these lasers is selectively absorbed by the TCO layer, which leads to vitrification of the TCO layer.
  • a suitable vitrification process comprises the use of a “green” (532 nm) laser. This laser melts the silicon layer. The silicon layer trans-ports the heat to the TCO layer, which is then vitrified.
  • the TCO layer is present on a permanent substrate, e.g., a glass substrate or a temperature resistant transparent polymer substrate, when the vitrification process is carried out.
  • a permanent substrate is a substrate which will not be removed before the solar cell is ready for use.
  • the TCO layer is be present on a temporary substrate when the vitrification process is carried out, e.g., when use is made of a process as described in WO 98/13882 or WO99/49483.
  • a temporary substrate is a substrate which will be removed from the TCO before the solar cell is suitable for use.
  • the TCO layer is on a photovoltaic layer when the vitrification process is carried out. This embodiment may be less preferred.
  • the vitrification process can be carried out on the TCO layer as such, that is, by providing energy to the TCO layer directly, for example by using a suitable laser.
  • the vitrification step with the provision of a groove through a photovoltaic layer, e.g., using a suitable laser.
  • the amount of energy provided by the laser is selected to be such that a groove is provided through the PV layer and at the same time sufficient to vitrify the TCO layer below the PV layer.
  • This process is especially effective when a silicon-based PV layer is used. Because silicon is a good energy absorber when the appropriate laser is selected, the silicon layer will become very hot, which will contribute to the vitrification of the TCO layer.
  • the vitrification step with the provision of a groove through a photovoltaic layer and a back electrode layer, for example using a suitable laser.
  • the amount of energy provided by, for example, the laser is selected to be such that a groove is provided through the back electrode layer, through the PV layer and at the same time sufficient to vitrify the TCO layer below the PV layer.
  • the laser is selected to be such that a groove is provided through the back electrode layer, through the PV layer and at the same time sufficient to vitrify the TCO layer below the PV layer.
  • the series connection is established by ensuring that the front electrode of one cell and the back electrode of an adjacent cell are electrically connected in an interconnect while the front and the back electrode are each interrupted at different sides of the interconnect.
  • the insulating interrupt in the TCO layer is made by vitrification. Depending on the manufacturing method of the interrupt, it may be accompanied by a groove in the PV layer and optionally through the back electrode. If a groove is present in these layers, it will be filled with an insulating material.
  • the interrupt in the back electrode is generally applied by making a groove using a laser and filling the groove with an insulating material. Depending on the manufacturing method of the interrupt, it may be accompanied by a groove in the PV layer. If a groove is present in the PV layer it will be filled with an insulating material.
  • strips of an insulating material may be applied at the location where the interrupting grooves are to be applied.
  • the insulating material will act as laser stop to prevent the formation of short-circuits by melting of the underlying material.
  • the insulating material may be applied on the TCO layer and/or on the PV layer, as applicable.
  • the interconnect can be established in various manners. It can be established by applying a groove through the PV layer and filling it with a conductive material.
  • the groove may or may not extend through the TCO layer, through the back electrode layer, or through both the TCO layer and the back electrode layer. This will depend, int. al., on the process step in which the groove is applied.
  • the conductive material which is used to fill the groove in the PV layer is back electrode material. If the PV layer is an amorphous Si layer, the conductive connection can also be established by fusing the amorphous Si layer with the back electrode. If the PV layer is an amorphous Si layer, the interconnect can also be established by recrystallising the Si into a conductive material. This option is less preferred, however. Extending of the groove for the interconnect through the TCO layer may be less preferred where it is desired not to damage the layer underlying the TCO layer.
  • interconnect and the interrupting grooves are applied is not critical and will depend on what is most suitable in the specific process applied.
  • the width of the interconnect and the interrupts generally is determined by the following considerations. At the sites of the interconnect and the interrupts, the solar cell is unable to convert light into electricity. In view of this, the interconnect and the interrupts have to be as narrow as possible. On the other hand, they have to be wide enough to ensure that the desired effect, the interruption of the different layers with sufficient insulation and the connection of the front and the back electrode with sufficient conductivity, is attained.
  • the interrupts generally have a width of 2 to 400 microns, preferably of 5 to 250 microns.
  • the interconnect generally has a width of 0.1 to 200 microns, preferably of 5 to 50 microns.
  • the distance between the interrupts and the interconnect of an individual series connection, where they are present in different grooves is generally between 5 and 500 microns, more in particular between 10 and 250 microns.
  • the strips of an insulating material that may be applied at the location where the interrupts are to be applied should be wide enough to allow for easy provision of the interrupting grooves within the width of the strips.
  • the strips have a width between 25 and 1,000 microns, preferably between 50 and 400 microns, more preferably between 50 and 200 microns.
  • FIG. 1 This embodiment is illustrated in FIG. 1 . It is important to note that the present invention is not limited to or by what is depicted in this figure.
  • FIG. 2 This embodiment is illustrated in FIG. 2 . It is important to note that the present invention is not limited to or by what is depicted in this figure.
  • FIG. 3 This embodiment is illustrated in FIG. 3 . It is important to note that the present invention is not limited to what is depicted in this figure.
  • a back electrode ( 4 ) is applied onto the PV layer, and a groove is provided in the back electrode ( 4 ) down to the PV layer or, if present, down to the insulating strip.
  • the provision of this groove can be done by applying the back electrode and then providing a groove, e.g., using a laser. It is also possible to apply a lift-off compound on the PV layer, then provide a back electrode onto the PV layer and the lift-off compound, and then removing the lift-off compound.
  • the present invention also pertains to solar cell systems comprising a transparent conductive oxide layer, a photovoltaic layer, and a back electrode, the system being divided into at least two individual cells with the transparent conductive oxide layer of a cell being connected through a conductive interconnect with the back electrode of an adjacent cell, wherein the transparent conductive oxide layer is provided with an insulating interrupt on one side of the interconnect and the back electrode is provided with an interrupt on the other side of the interconnect, characterised in that the interrupt in the transparent front electrode is made up of vitrified transparent conductive oxide.
  • vitrified interrupt in the TCO layer is accompanied by insulating material in the PV layer above the interrupt (e.g as in FIG. 3 ). In another embodiment the vitrified interrupt in the TCO layer is not accompanied by insulating material in the PV layer above the interrupt (e.g., as in FIGS. 1 and 2 ).
  • the interconnect is filled with back electrode material (e.g., as in FIGS. 1 and 3 ). In another embodiment the interconnect is filled with a separate conductive material (e.g. as in FIG. 2 ). In a further embodiment the interconnect is provided by fusing the back electrode with a silicon PV layer.
  • the interconnect may be made by a groove through the PV layer only (e.g. as in FIGS. 1 and 3 ), by a groove through the PV layer and the back electrode (e.g., as in FIG. 2 ), or by a groove through the PV layer, the back electrode and the transparent conductive oxide layer (not illustrated).
  • the interrupt in the back electrode layer is accompanied by insulating material in the PV layer below the interrupt. In another embodiment the interrupt in the back electrode is not accompanied by insulating material in the PV layer below the interrupt (e.g., as in FIGS. 1 , 2 , and 3 ).
  • a further, and preferred, embodiment of the present invention comprises the general steps of
  • the crux of this embodiment is ensuring that on at least one side of the groove in the PV layer a non-vitrified section of the transparent conductive oxide layer is not overlayed with insulating PV layer material.
  • the non-vitrified section of the TCO layer is not overlayed by PV material at all.
  • the non-vitrified section of the TCO layer is overlayed with PV layer material which has become conductive, for example, in the case, for example, a silicon-based PV layer, by melting and recrystallising of the PV layer.
  • the interconnect between the transparent conductive oxide layer and the back electrode is made by said non-vitrified section of the TCO being in conductive connection directly with back electrode applied in the groove (in the case where the non-vitrified section of the TCO layer is not overlayed by PV material), or by said non-vitrified section of the TCO being in conductive connection with a conductive section of the PV layer, which in turn is covered with back electrode.
  • FIG. 4 The version of this embodiment in which the interconnect between the transparent conductive oxide layer and the back electrode is made by the non-vitrified section of the TCO being in conductive connection directly with back electrode applied in the groove is illustrated in FIG. 4 .
  • FIG. 5 The version of this embodiment in which the interconnect between the transparent conductive oxide layer and the back electrode is made by the non-vitrified section of the TCO being in conductive connection with a conductive section of the PV layer, which in turn is covered with back electrode is illustrated in FIG. 5 .
  • the area indicated with the arrow is the part of the PV layer which has become conductive, e.g., through melting and recrystallisation.
  • a groove can be provided through the PV layer onto the transparent conductive oxide layer while, applying such an amount of energy that the section (v) of the TCO below the groove is vitrified, ensuring that on at least one side of the groove a non-vitrified section of the transparent conductive oxide layer is not overlayed with insulating PV layer material.
  • said groove is applied in two steps, wherein in a first step a relatively broad groove is applied through the silicon layer, in which the silicon is removed in such a way that the underlying TCO is not vitrified, while in a second step a strip of TCO layer is vitrified within the first groove, in another embodiment, said groove is applied in two steps, wherein in a first step a narrow groove is applied through the silicon PV layer in such a manner that vitrification of the TCO layer below the groove is ensured, while in a second step a broader groove is applied in the silicon PV layer over the first groove, in which at the edges of the narrow groove silicon is removed or recrystallised into a conductive form while the TCO below the broader groove is not vitrified further.
  • An advantage of this embodiment is that it allows good process control.
  • the groove is applied in a single step, where the amount of energy applied is selected such that a curved groove profile is obtained, in which the vitrified section of the transparent conductive oxide layer is narrower than the groove in the PV layer, e.g., as illustrated in FIGS. 4 and 5 .
  • the molten PV layer may “withdraw”to the edges of the groove, as a result of which a non vitrified section of the transparent conductive oxide layer becomes (substantially) free of PV layer, as illustrated in FIG. 4 .
  • the PV layer above part of the non-vitrified section of the TCO to become conductive, e.g., through melting and recrystallisation, as illustrated in FIG. 5 .
  • the present invention also pertains to a solar cell system comprising a transparent conductive oxide layer, a photovoltaic layer, and a back electrode, the system being divided into at least two individual cells with the transparent conductive oxide layer of a cell being connected through a conductive interconnect with the back electrode of an adjacent cell, wherein the transparent conductive oxide layer is provided with an insulating interrupt on one side of the interconnect and the back electrode is provided with an interrupt on the other side of the interconnect, characterised in that the interrupt in the transparent front electrode is made up of vitrified transparent conductive oxide, the interconnect between the transparent conductive oxide layer and the hack electrode being made by a non-vitrified section of the TCO being in conductive connection directly with back electrode applied in the groove, or by a non-vitrified section of the TCO being in conductive connection with a conductive section of the PV layer, which in turn is covered with back electrode.
  • F-doped SnO2 is preferred, because it can form a desired crystalline surface with a columnar light scattering texture when applied at a temperature above 400° C., preferably in the range of 500 to 600° C.
  • the TCO can be applied by means of methods known in the field, e.g., by means of Metal Organic Chemical Vapour Deposition (MOCVD), sputtering, Atmospheric Pressure Chemical Vapour Deposition. (APCVD), PECVD, spray pyrolysis, evaporation (physical vapour deposition), electrodeposition, screen binding, sol-gel processes, etc. It is preferred to apply the TCO layer at a temperature above 250° C., preferably above 400° C., more preferably between 500 and 600° C., so that a TCO layer of the desired composition, properties and/or texture can be obtained.
  • the thickness of the TCO layer is generally between 200 and 2000 nm, more in particular between 500 and 1000 nm.
  • PV layer or “photovoltaic layer” comprises the entire system of layers needed to absorb the light and convert it into electricity. Suitable layer configurations are known, as are the methods for applying them.
  • Various thin film semiconductors can be used in manufacturing the PV layer. Examples are amorphous silicon (a-Si:H, microcrystalline silicon, polycrystalline silicon, amorphous silicon carbide (a-SiC), amorphous silicon-germanium (a-SiGe), and a-SiGe:H.
  • the PV layer in the solar cell foil according to the invention may comprise CIS (copper indium diselenide, CuInSe2) PV cells, Cu(In,Ga)(Se,S)2 PV cells, CdTe (cadmium telluride) cells and/or dye sensitised and organic PV cells.
  • CIS copper indium diselenide
  • CuInSe2 Cu(In,Ga)(Se,S)2 PV cells
  • CdTe cadmium telluride
  • dye sensitised and organic PV cells dye sensitised and organic PV cells.
  • tandem cells may also be applied. Suitable combinations include amorphous silicon with microcrystalline silicon, and amorphous silicon with amorphous silicon-germanium.
  • the PV layer preferably is a silicon layer when the TCO comprises a fluorine-doped tin oxide.
  • the PV layer will generally comprise a set, or a plurality of sets, of p-doped, intrinsic, and n-doped amorphous silicon layers, with the p-doped layers being situated on the side receiving the incident light.
  • the overall thickness of the PV layer will generally be of the order of 100 to 3000 nm.
  • the back electrode is also not critical to the present invention. Preferably it serves both as reflector and as electrode. Generally, the back electrode will have a thickness of about 50 to 500 nm, and it may comprise any suitable material having light reflecting properties, preferably a metal, for example, aluminium, silver, or a combination of layers of both. These metal layers preferably can be applied at a comparatively low temperature, e.g., below 150° C., by means of for instance (in vacuo) physical vapour deposition or sputtering. In the case of silver, it is preferred to first apply an adhesion promoter layer.
  • TiO2 and ZnO are examples of suitable materials for an adhesion promoter layer and have the advantage of also possessing reflecting properties when applied in a suitable thickness, e.g., of the order of 20-200 nm, in particular 50-100 nm.
  • the nature of the insulating material used to fill grooves is not critical to the process according to the invention. It is within the scope of the skilled person to select a suitable material. As will be clear to the skilled person, the material to be selected must be able to withstand the conditions under which the solar cell foil is to be employed, e.g., in terms of UV, moisture, and temperature resistance. Examples of suitable materials are insulating synthetic resins such as polyurethanes, epoxy resins, epoxy amines, polyesters, and acrylates. Preferred methods of applying the insulating material are screen printing, ink jet, and dispensing techniques. Other suitable methods of applying the insulating material will be obvious to the skilled person. The insulating strips also can be made of said insulating materials and be applied, e.g., by means of ink jet, dispensing, or other printing techniques.
  • the interconnect can be established in various ways. If it is established by way of first providing a groove and then filling it with a conductive material, suitable conductive materials include coatings of cross-linked polymers, such as the aforementioned ones, to which a conductive filler, such as particles of silver or flocks of nickel, is added. Such coatings are known to the skilled person. The coatings can be applied using well-known methods such as screen printing, printing, dispensing, or spraying techniques. It is also possible to provide a soldered connection. Alternatively, the conductive connection can be established via flame spraying of metals, e.g., aluminium. The technology of flame spraying is known to the skilled person.
  • the present invention can, int. al., be used in providing a series connection in a solar cell foil manufactured using a temporary substrate.
  • Processes for manufacturing solar cell foils using a temporary substrate are known in the art. They are, e.g., described in WO 98/13882, WO 99/49483, WO 01/47020, WO 01/78165, WO 03/001602, and WO 05/015638, the disclosures of which are incorporated by reference.
  • a temporary substrate has to meet a number of requirements. It has to be sufficiently heat-resistant to withstand the conditions prevailing during the manufacture of the solar cell foil, more particularly, during the deposition of the TCO and the PV layer. It has to be strong enough to support the solar cell foil during its manufacture. It must be easily removable from the TCO layer without the latter being damaged in the process. Within the framework of these guidelines the skilled person will be able to select a suitable temporary substrate. Reference is made to the above-mentioned publications. It preferably is a foil of a metal or metal alloy. The main reasons for this are that in general such foils are resistant to high process temperatures, are slow to evaporate, and can be removed comparatively easily using known etching techniques.
  • Suitable metals include steel, aluminium, copper, iron, nickel, silver, zinc, molybdenum, and alloys or multi-layers thereof. For economic reasons among others it is preferred to employ Fe, Al, Cu, or alloys thereof. Given their performance (and taking into account the matter of cost) aluminium, iron, and copper are most preferred. Suitable etchants and techniques for removing metals are known in the art.
  • a non-reducing diffusion barrier layer e.g., an anti-corrosion layer, more particularly, zinc oxide.
  • the temporary substrate may be pro-vided with a transparent insulation spacer. Because of its transparency, this layer can be left on the TCO to serve as a protective layer for the TCO.
  • the transparent insulation spacer preferably is made of glass.
  • the temporary substrate preferably is as thin as possible. Of course, it has to be such that other layers can be deposited on it and it has to be able to hold these together, but this generally does not require it to be more than 500 microns (0.5 mm) thick.
  • the thickness preferably is in the range of 1 to 200 microns (0.2 mm). Depending on the modulus of elasticity, the minimum thickness for a large number of materials will be 5 microns. Accordingly, a thickness of 5-150 microns, more particularly of 10-100 microns, is preferred.
  • the solar cell foil may be provided with a carrier over the back electrode, or with an encapsulant, both as known to the skilled person.
  • carrier over the back electrode is preferred where use is made of a temporary substrate process as described in the above references.
  • Suitable carrier layer materials include thin films of polymer, but also, for example, metal foils onto which an insulating (di-electric) surface layer has been applied
  • the thickness of the carrier preferably is 75 microns to 10 mm. Preferred ranges are 100 microns to 6 mm and more in particular 150 microns to 300 microns.

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Computer Hardware Design (AREA)
  • Power Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Sustainable Development (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Energy (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Photovoltaic Devices (AREA)
US12/734,905 2007-12-21 2008-12-17 Method for providing a series connection in a solar cell system Abandoned US20100252089A1 (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
EP07123962 2007-12-21
EP07123962.8 2007-12-21
EP08101700A EP2073269A1 (fr) 2007-12-21 2008-02-18 Procédé pour la fourniture d'une connexion en série dans un système de cellule solaire
EP08101700.6 2008-02-18
PCT/EP2008/067692 WO2009080640A2 (fr) 2007-12-21 2008-12-17 Procédé pour assurer une connexion en série dans un système de piles solaires

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US20100252089A1 true US20100252089A1 (en) 2010-10-07

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US (1) US20100252089A1 (fr)
EP (1) EP2073269A1 (fr)
JP (1) JP4633201B1 (fr)
KR (1) KR20100102134A (fr)
CN (1) CN101952965B (fr)
TW (1) TW200939496A (fr)
WO (1) WO2009080640A2 (fr)

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Publication number Priority date Publication date Assignee Title
US10236401B2 (en) * 2016-08-03 2019-03-19 Panasonic Corporation Solar cell module and method of producing the same
US11302829B2 (en) * 2017-03-29 2022-04-12 Kaneka Corporation Photovoltaic device and method for manufacturing photovoltaic device

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Publication number Priority date Publication date Assignee Title
DE102010027747A1 (de) * 2010-04-14 2011-10-20 Robert Bosch Gmbh Verfahren zur Herstellung eines Photovoltaikmoduls mit rückseitenkontaktierten Halbleiterzellen und Photovoltaikmodul
US20120000519A1 (en) * 2010-07-01 2012-01-05 Primestar Solar Transparent electrically conductive layer and method for forming same
DE102011007544A1 (de) * 2011-04-15 2012-10-18 Von Ardenne Anlagentechnik Gmbh Verfahren und Vorrichtung zur thermischen Behandlung von Substraten
FR2985606B1 (fr) * 2012-01-11 2014-03-14 Commissariat Energie Atomique Procede pour realiser un module photovoltaique avec deux etapes de gravure p2 et p3 et module photovoltaique correspondant.

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US4929281A (en) * 1987-04-14 1990-05-29 Nukem Gmbh Method for producing thin-film solar cells in a series-connected array
US20010037823A1 (en) * 1999-12-21 2001-11-08 Erik Middelman Process for manufacturing a thin film solar cell sheet with solar cells connected in series
US20040219710A1 (en) * 2001-06-21 2004-11-04 Dubbeldam Gerrit Cornelis Manufacturing a solar cell foil connected in series via a temporary substrate
US20050272175A1 (en) * 2004-06-02 2005-12-08 Johannes Meier Laser structuring for manufacture of thin film silicon solar cells

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CA2267076C (fr) 1996-09-26 2005-01-25 Akzo Nobel Nv Procede de fabrication d'une feuille photovoltaique
EP0948004A1 (fr) 1998-03-26 1999-10-06 Akzo Nobel N.V. Procédé de fabrication d'une cellule photovoltaique contenant un colorant
JP2001291502A (ja) 2000-04-05 2001-10-19 Toyo Kohan Co Ltd 密閉型電池、封口体及び外装缶

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US4929281A (en) * 1987-04-14 1990-05-29 Nukem Gmbh Method for producing thin-film solar cells in a series-connected array
US20010037823A1 (en) * 1999-12-21 2001-11-08 Erik Middelman Process for manufacturing a thin film solar cell sheet with solar cells connected in series
US20040219710A1 (en) * 2001-06-21 2004-11-04 Dubbeldam Gerrit Cornelis Manufacturing a solar cell foil connected in series via a temporary substrate
US7276658B2 (en) * 2001-06-21 2007-10-02 Akzo Nobel N.V. Manufacturing a solar cell foil connected in series via a temporary substrate
US20050272175A1 (en) * 2004-06-02 2005-12-08 Johannes Meier Laser structuring for manufacture of thin film silicon solar cells

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10236401B2 (en) * 2016-08-03 2019-03-19 Panasonic Corporation Solar cell module and method of producing the same
US11302829B2 (en) * 2017-03-29 2022-04-12 Kaneka Corporation Photovoltaic device and method for manufacturing photovoltaic device

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JP4633201B1 (ja) 2011-02-23
WO2009080640A3 (fr) 2009-09-17
EP2073269A1 (fr) 2009-06-24
KR20100102134A (ko) 2010-09-20
JP2011507297A (ja) 2011-03-03
TW200939496A (en) 2009-09-16
WO2009080640A2 (fr) 2009-07-02
CN101952965B (zh) 2012-07-18
CN101952965A (zh) 2011-01-19

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